1.

Introduction

CHAPTER 1: INTRODUCTION

1.1 Transformer Engineering and its Importance in Power System

Transformer is an electrical device which alters or transforms voltage and
current from one level to another level in power system without change of
frequency. The transformation of power between the circuits remains
unchanged, ‘except for a typically small ‘loss which occurs in the process.
This alteration only possible when alternating current (A.C) or transient”
electrical conditions are present. Due to technological enhancement latest
transformers differ significantly from the early one, but the operating principle
is still the same.”

As per National and International standards like IEC/ ANSI/ IEEE (10) (IEEE
standard terminology for power and distribution transformers, IEEE Std, C. 57
12 80-2002), It is defined as a static devise which consists of electrical and
magnetic circuit like two or more windings and core respectively, for
introducing mutual coupling between electric circuits(1).Transformer’s primary
and secondary windings are not electrically connected but electromagnetically
coupled. The basic working principle of transformer is an electromagnetic
induction. It is the main equipment or heart of the power system for
transmission as well as distribution of electrical energy.

As we know the bulk power is to be transmitted from generation station to the

consumers through long distance power transmission. Voltage must be
stepped up to EHV or UHV level to restrict the transmission loss. Now a days
power transmission is accomplished with voltages in the range of 100-500 kV
and more recently with voltages as high as 765kV.” These high voltages are
incompatible with safe usage” in households or” factories. This is the reason
to incorporate the transformer in electrical network. In addition, generators are
for practical reasons such as cost and efficiency, designed to produce
electrical power at voltage levels of 10 to 40 kV A.C. Thus there is also a need
for transformers at the sending end of the line to boost the generator voltage
up to the required transmission levels.”Fig.1.1 shows a simplified version of a
power system with actual voltages indicated.

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 1.Introduction

Figure 1.1 Simplified layout of Power System

In power systems, usually more than one voltage step down from
transmission to final distribution is required. This is achieved by using
transformer. Fig.1.2 shows a transformer situated in a switch yard. The high
voltage input line is being connected to the transformer primary winding to
convert it to lower voltage power for local use from secondary winding of
transformer. The secondary power could be further stepped down in voltage
before” reaching to the end consumer. A transformer can be used for lighting
or to provide power to house, town or big industry.

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 1.Introduction

Figure 1.2 Transformer Situated in Substation

Due to complex interconnected system, there is always a chance of voltage

drop or boost. So there is often a need to make fine voltage tuning” to
compensate voltage drops in the lines and other equipment. These voltage
drops depends on the load current. So they vary throughout the day. Here the
concept of tap changing device is applicable. These are the devices which
add or subtract turns from a winding, thus altering its voltage. It can be done
while a transformer is on-load or by the disconnection of the load from a
transformer. Respectively it is nomenclature as on-load or off-load tap
changers.”

While designing a transformer, the terms like electromagnetism, electrical

circuit analysis, insulation coordination, magnetic circuit analysis, heat and
mass transfer, thermodynamics etc. must be well acquainted.

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 1.Introduction

The main aim of the transformer design is to obtain the dimension of all the
parts of transformer according to the specifications given by the customer to
the manufacturer. Optimization of transformer design is a very complex task in
which a researcher has to make sure that compatibility with obligatory
specifications are met, while keeping manufacturing cost low. The optimum
design of transformer gives assurance to the manufacturer a product of high
performance at a relatively low cost. The design can be optimized either by
minimizing of manufacturing cost or total owning cost or transformer active
part cost or active part mass or losses or maximization of transformer
apparent power within some specified requirements.

1.2 Types of Transformers

It can be designed based on different, types and applications. With respect to
power system there are three types Viz. (i) The distribution transformers for
rated power up to, 2.5 MVA and voltage up to 36 kV.(ii) The power
transformer for rated power 1000 MVA and 1500 kV voltage.(iii) The
generator transformer mostly use to connect generator output to rest of the
power system as a step up voltage transformer. It can also be defined based
on construction. There are two types of construction (i) core type and (ii) shell
type. It can be classified based on application (i) Voltage transformer (ii)
Current-Transformer (iii) Furnace, transformer (iv) Regulating transformer (v)
Converter-transformer (vi) Rectifier duty transformer (vii) Mining transformer
(viii) Phase, shifting transformer (ix) Motor starting transformer (x) Traction
transformer(xi) High frequency transformer (xii) Welding transformer (xiii) High
voltage testing transformer (xiv)) Short circuit testing transformer (xv)
Earthling, transformer and (xvi) Dry type transformer. The cooling
methodology is also giving’ identification to the transformer like (i) Air Natural
(AN)(ii)Air-Blast(AB) (iii) Oil Natural Air Natural (ONAN) (iv) Oil Natural Air
Forced (ONAF) (v) Oil Natural Water Forced (ONWF) (vi) Air Forced Air
Natural (AFAN) (vii) Oil Forced Air Natural (OFAN) (viii) Oil Forced Air Forced
(OFAF) )(ix) Oil Forced Water Forced (OFWF). Number (iv) to (ix) is used for
large size power transformer, as it provides better cooling.

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 1.Introduction

(A)

(B)

(C)

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 1.Introduction

(D)

(E)

(F)

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 1.Introduction

(G)

(H)
Figure 1.3 Different types of transformers (A) Step up & Step down
Transformer (B) Core & Shell type transformer (C) Generator transformer
(D) Power & distribution transformer (E) Single & Three phase
transformer (F) Furnace and Dry type transformer (G) Traction &
Rectifier duty transformer (H) Testing transformer.

Design of a transformer is a very complex task. While designing core and

winding, there are various parameters plays a vital role like impendence (%Z),
efficiency, flux density, current’ density, No load, load losses, which are totally’
depend up on the construction method and the selection of material of core
and winding. To design the core, first is the selection of flux density and grade
of material. There are different types of material are available in market for
core design like CRGO and Amorphous. CRGO having various grades viz.

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M4, M5, M6, ZDkh, Zh90, MOH, Z0h. In core material, the content of silicon
steel should be in the range of 3 to 4 %, to minimize the losses. To minimize
eddy current loss, laminations are provided on core individual plates.

On other side there are different types of winding used by designer for a
different kV class and current rating. It can be classified as helical winding,
cross over coils, layer winding, continuous disc winding, interleaved disc
winding, counter shield winding for current rating 6000 amps., 1200 amps., 40
amps. respectively for’ (3) design of transformer made as per customer
requirement, operating voltage class and kVA rating. Before construction of
transformer, manufacturer makes a computer based Transformer design and
calculate the design parameter. ‘Earlier manufacturers design transformer in
excel sheet. But now a day various software are available. After calculating all
the parameters, transformer design is being processed, transformer is being
manufactured and various tests are performed on it in order to validate the
design. The research related transformer engineering and design optimization
is going to be wider. ‘Numerous researches are being done in this area.
Transformer design still remains a challenge due to the conflicting
requirements that to be satisfied like electrical ratings, efficiency, temperature
rise, rational use of natural resources and cost. Various methodologies are
being applied to design a transformer; it may be software based or analytical
methodology. To meet customer requirement manufacturer or designers focus
on optimization technique. It is based on maximization or minimization of
objective functions which includes various constraints. Objective functions like
minimization of cost, losses, mass, material cost, manufacturing cost or
maximization of rated power are considered for TDO. The design of
transformer is not only a process to comply customer requirement but also to
comply the requirement of national and international standards like IS, IEC,
BS, and IEEE etc.’

In this thesis, the transformer design methodology and design optimization is

covered in detail. Optimum transformer design based on the given
specifications is obtained, using available materials economically to achieve
lower cost, reduced size and better operating performance. Different

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optimization techniques and MATLAB based optimization tool has been

applied to obtain optimum design of transformer. The effectiveness of the
proposed method and MATLAB based optimization tool approach has been
validated with the prototype transformer.

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